ProSIM has a high level of expertise in manufacturing and metal forming simulation to predict the metal flow, forming limits, defect formation
during the manufacturing by virtual manufacturing process.
Process Simulation R&D
Our Manufacturing Process SImulation COE is has the experience and facility to simulate
Processes such as
- Sheet Metal Forming
- Hydroforming
- Tailor Welded Blanks
- Powder Metallurgy
- Casting Simulation
- Heat Treatment
- Welding
- Forging
- Rolling
are all simulated using this procedure to optimize the process and the
tool and process design.
Sheet Metal Forming
- Stamping / Deep drawing
-
Hydroforming ( Tube and Sheet)
-
Tailor welded blank
-
Stretch forming
- Springback estimation
- Prediction of thinning /stretching
- Tool and die design verification
- Formability verification
- Prediction of wrinkles and folds
Hydroforming
Tailor Welded Blanks
Powder Metallurgy
P/M Components & Processes; Design & Optimization
- compaction simulation
- densification prediction
- spring back estimation,
- sintering simulation
- shrinkage & distortion
- prediction, tool stress and
- deflection estimation
- tooling/process design
- optimization
Casting
- Sand (Grey, Ductile,Steel, Al ) / Investment casting
- Gravity / High Pressure die casting
- Permanent mold / Shell Casting
- Develop die / gating design and process plan
- Verify the Tool design by FEM simulation and analysis
- Reducing rejections due to porosity formation, cold shuts.
- Yield improvement.
- Optimization of riser
Heat treatment
- Residual stress prediction
- Distortion prediction
- Distribution of metallurgical phases
(Austenite, bainite, ferrite,
martensite etc)
- Grain size and Hardness distribution
- Location of cracks.
- Tool failure analysis
Welding Simulation
ProSIM has high level of experience in Modeling of Weld to predict :
> Residual stress
> Distortion
> Heat Affected Zone (HAZ)
> Fatigue, fracture and durability of welded structures
TIG/ MIG/ LASER/ELECTRIC ARC/ ELECTRON BEAM/ ELECTRICAL SPOT RESISTANCE
welding (single/ multi pass) are simulated using FEM tools.
The Process Model can be used for
> Weld sequence optimization
> Complete understanding of the welded component during
welding, cooling and in service
ProSIM has worked on fatigue, crash, and impact resistance analysis and microstructural analysis
of weldings; development of alternate welding processes, (friction / friction stir/ tubular welding/
deformation resistance welding; and optimization of weld sequence to minimize the weld distortion.
Forging
- Develop die design and process plan
- Verify the die / tool design by FEM
simulation and analysis
- Modify tool design for new materials.
- Yield improvement / flash reduction,
reducing rejections
- Reducing number of stages, cycle time
- Optimize the metal flow
- Optimize the power / press tonnage
- Predict stress, strain, strain rate,
stresses, temperature in work
piece and dies.
- Predict defects
laps / folds/ underfils
- Die stress analysis
Rolling
- Shape rolling, profile rolling.
- Sheet rolling, HSM modeling,
- Offline simulator to predict
microstructure in rolling.
- Heat transfer modeling of the
ROT, down coiler.
- Predicting of camber angle.
